MACHINERY OUTFITTING WORKSHOP
NAME : K.J.DILSARA
SERVICE NUMBER : 7400985
DATE : 28/08/2024
CONTENT
❖ Introduction
❖ Pipe Treatment Methods
• Pipes Pickling Procedure
❖ Pipes Cutting
• Cutting Procedure using saw cutter
❖ Pipes Fabrication with given design
❖ Pipes Numbering & Colour Codes using pipes systems
❖ Pipes Pressure Testing
❖ Emergency Valve Cut-Off Procedure
❖ Pipes Welding Procedure
❖ Machinery Installation and Alignment
INTRODUCTION
The main purpose of a machinery outfitting workshop in the dockyard is to prepare, assemble, and install various
machinery and mechanical systems on new ships or other marine vessels. This workshop is crucial in ensuring that all
mechanical components, such as engines, generators, pumps, and other equipment, are correctly outfitted, tested, and
ready for operation.
Machinery Outfitting Workshop Operations
• Assembly and Installation: Assembling machinery and equipment, including engines, turbines, compressors,
and other mechanical systems, and installing them on the new vessel.
• Alignment and Balancing: Ensuring that machinery is properly aligned and balanced within the ship to
prevent operational issues and to ensure smooth functioning.
• Pipes Fabrication: Fabrication of all pipes units required for the ships.
• Piping: Installing and connecting necessary piping and other auxiliary systems that support the operation of
the machinery.
• Checking after installation: Conducting quality checks and inspections to ensure that all machinery meets
required specifications and standards before the vessel is launched.
Figure 01 : Machinery Outfitting Workshop
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Pipe Treatment Methods
❖ Pickling, Galvanizing, Stainless Steel, Flushing are used as pipe treatment methods.
Pipes Pickling Procedure
• Pipes were inspected to ensure they were free from any major defects or damages before pickling.
• Pipes were pre-cleaned to remove any loose debris, dirt.
• Then firstly pipes are dipped in NaOH(8-12% concentration) bath at 80ċ for around 1.5 – 2 hrs.
• In this stage removed all paints, oils, grease on pipe surface.
• Then the pipes are moved to the next phosphoric acid bath (H3PO4 ) (11-15% concentration) in room
temperature (30 min).
• In this stage removed the rust and corrosion on the pipes.
• Then the pipes are pressure washed using water.
• Then the pipes are moved to the bath No 03, It is again NaOH(2-3% concentration) at the room
temperature (3 min).
• In this stage neutralizes the pipes surface.
• Then cleaned the pipes using dry air.
• Finally the pipes are send for the painting.
Safety
• Use acid-resistant gloves, goggles, face shields, aprons, respirators, and steel-toed boots.
• Ensure proper ventilation and use fume hoods to remove harmful fumes.
• Have emergency showers, eye wash stations, first aid kits, and a clear emergency response plan.
• Treat and neutralize waste, and prevent spills from reaching the environment.
• Train workers on chemical safety, PPE usage, and emergency procedures.
• Regularly inspect equipment and monitor air quality.
Figure 02 : Pickling Method
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Pipes Cutting
❖ In the machinery outfitting workshop, pipe cutting for ships involves using tools like saws and plasma cutters
to precisely cut pipes according to detailed drawings or blueprints. These drawings show the exact sizes and
shapes needed for the pipes to fit perfectly into the ship’s systems, such as plumbing, fuel lines, and exhaust
systems. This process ensures that the pipes are accurately prepared for installation, following the design
specifications of the ship.
Cutting Operations
• Plasma Cutter : A plasma cutter is used for cutting metal pipes with precision and speed. It operates by
generating a high-temperature plasma arc that melts the metal, while an inert gas blows the molten material
away, creating a clean cut.
• Saw Cutter : Saw cutters are used to cut pipes into specific lengths. They use a sharp, toothed blade to saw
through the metal.
Cutting Procedure using saw cutter
• The pipe was securely clamped in the saw’s vise to ensure stability and prevent movement during the cutting
process.
• The required length of the pipe was measured, and a cutting line was marked on the pipe’s surface with chalk
or a marker.
• The saw machine was set to the correct speed and tension based on the pipe's material. Adjustments were made
as necessary to ensure smooth cutting.
• The saw was turned on, and the pipe was cut along the marked line.
• Coolant path was opened in this movement. (Soluble oil use for this)
• Then the pipe was checked for a smooth cut, and any rough edges were cleaned up.
• Finally the pipe was removed and checked to ensure it met the required length.
Safety
• Use safety glasses, gloves, hearing protection, and avoid loose clothing.
• Check the blade, ensure safety guards are in place, and clamp the pipe securely.
• Keep hands clear of the blade, maintain a steady feed rate, and stand to the side of the cutting path.
• Know the location of the emergency stop and have a first aid kit nearby.
• Handle cut pipes with care, clean up debris, and maintain the machine regularly.
Figure 03: Saw cutter & Soluble oil
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Pipes Fabrication with given design
Procedure
• The pipe sections were marked according to the design for any necessary bends, joints, or fittings.
• The pipe sections were welded together according to the design with temporarily securing them with small
weld dots while maintaining a slight clearance between the pipe joints, ensuring proper alignment and
connection.(using Metal Active Gas weld)
• Attached the flanges to the pipes by placing small ring between the outer surface of the flange and the pipe end
to ensure proper clearance.
• The fabricated pipe was inspected to ensure that it matched the design specifications in terms of dimensions,
alignment.
• The assembled pipes were send to the final welding process.
Safety
• Use safety glasses, gloves, welding helmets, and protective clothing.
• Inspect tools, secure pipes, and ensure proper ventilation during welding.
• Lift pipes safely and keep the work area clear of obstacles and debris.
• Have fire extinguishers nearby and keep flammable materials away from the work area.
Figure 04 : Pipe Fabrication
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Pipes Numbering
250-201-100-804-062-004
Ship Docked Pipe diameter System Line number Spool
number zone number number
195 B1 / 195 B2
195 : Length of the pipe
B1 : One side bevelling
B2 : both sides bevelling
Colour Codes using pipes systems
• In marine ships the colour code for pipelines identification are standardized to ensure safety and proper
maintenance here are the commonly used colour codes.
o Fuel : Brown
o Lub oil : Yellow
o Fresh Water : Blue
o Sea water : Green
o Steam : White
o Air : Light Blue
o Blige : Black
o Fire fighting system : Red
Pipes Materials
Figure 05 : Colour Codes
• Stainless steel
• Aluminium
• Mild steel
• Copper
• Low Carbon alloy steel
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Pipes Pressure Testing
Procedure
• The pipe system was thoroughly cleaned to remove any debris or contaminants.
• All pipe ends and connections were sealed using caps, plugs, or flanges to ensure no leaks during testing.
• The pipe system was filled with water or another test fluid to eliminate air pockets and ensure complete
coverage.
• The pipe was gradually pressurized to the specified test pressure, as outlined in the design requirements. (3-
4 bar operation pressure)
• The pressure was maintained for a designated period while the system was monitored for any drops in
pressure or signs of leakage.
• All joints, welds, and connections were inspected for leaks or weaknesses using visual checks or leak
detection equipment.
• After the test, the pressure was slowly released to avoid any sudden drops that could damage the system.
• The test fluid was drained from the pipes, and the system was dried if necessary.
Safety
• Use safety glasses, gloves, and hearing protection.
• Increase pressure gradually and monitor gauges to stay within safe limits.
• Restrict access to authorized personnel and communicate clearly.
• Check for leaks and ensure secure connections before testing.
• Use relief valves and have an emergency shutdown plan.
Figure 06 : Pressure Testing
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Emergency Valve Cut-Off
Procedure
• The area around the emergency valve was cleared and prepared for inspection.
• The valve was visually inspected to ensure it was in good condition and free from visible damage or
obstructions.
• The emergency valve was manually operated to check for smooth and complete movement, ensuring it opened
and closed properly.
• The valve’s functionality was tested under operational pressure to verify it responded correctly and maintained
a secure seal when closed.
• The valve was activated in various scenarios to confirm it functioned properly during different system
conditions.
• The results of the check were recorded, noting any issues or required adjustments.
• The valve and its operation were reviewed to ensure compliance with safety and operational standards before
the system was approved for use.
Safety
• Operate the valve manually and ensure system pressure is within safe limits.
• Restrict access and maintain clear communication among team members.
• Check for leaks, ensure secure fittings, and inspect the valve for malfunctions.
• Know emergency procedures and have a first aid kit available.
Figure 07 : Emergency Valve Cut-Off
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Pipes Welding
Procedure
❖ After the fabrication process, some pipelines undergo a pre-installation phase on the ship to identify and
address any potential problems that could arise during installation. Once this phase is finished, components
that were initially tack welded are permanently joined using methods like Metal Active Gas (MAG) welding
and electric arc welding. The welding procedure is executed in three stages:
• Root Pass : The root pass is the first weld bead applied to the joint, establishing a strong foundation
for the rest of the weld.
• Filling : The filling pass adds material to the weld joint, building up the weld to the required
thickness.
• Capping : The capping pass is the final weld bead applied to the surface of the weld joint, providing
a smooth and finished appearance.
❖ This careful welding procedure ensures that the pipelines are strong, durable, and reliable within the ship’s
structure.
❖ Mostly used bevel angle 37.5º
Figure 08 : Bevel Angle
Common Welding Types
• MIG : Metal Inert Gas Welding
• MAG : Metal Active Gas Welding
• TIG : Tungsten Inert Gas Welding / GTAW : Gas Tungsten Arc Welding
Safety
• Use a welding helmet, safety glasses, flame-resistant gloves, protective clothing, and hearing
protection.
• Provide adequate ventilation, keep fire extinguishers nearby, and ensure proper lighting.
• Inspect and set up welding equipment correctly, and secure workpieces.
• Manage heat to prevent overheating and use shielding to avoid overexposure to fumes and UV
radiation.
• Know emergency procedures, have a first aid kit available, and be trained in first aid.
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Machinery Installation and Alignment
Common Installation and Alignment Procedure
• The installation area is assessed for structural integrity, space, and access.
• Machinery is inspected for completeness and damage before installation.
• Machinery is carefully lifted into position using cranes or other lifting equipment.
• The machinery is placed on foundation blocks or mounting pads that have been pre-installed.
• Initial alignment is checked to ensure machinery is roughly positioned according to specifications.
• Machinery is secured to its foundation with anchor bolts, ensuring stability and minimizing vibrations.
• Foundations may be grouted to fill any gaps and provide additional stability.
• Machinery is connected to other components, such as shafts or pumps, using couplings.
• Necessary piping are connected, ensuring all connections are secure and correctly configured.
• The machinery is tested for proper operation, including checking for vibrations, noise, and other operational
parameters.
• Machinery is tested under actual operating conditions to ensure it performs correctly and safely.
• After initial testing, final adjustments are made to alignment as needed.
• Machinery is calibrated to ensure accurate performance and efficiency.
Key Installations in a ship:
• Main Engine
• Generator
• Sewage Treatment Plant
• Ballast Water Treatment Plant
• Propeller Shaft
• Gearbox etc…
❖ There are several methods of alignment used :
• Piano wire alignment
• Dial gauge alignment
• Laser alignment etc……..
Figure 09: Machinery Installation
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Trainee Evaluation Form
Name K.J.Dilsara
Service Number 7400985
Department/Workshop Machinery Outfitting
Duration From 15/08/2024 To 28/08/2024
Poor Average Good Excellent
Description Total
(0 marks) (3 marks) (6 marks) (10 marks)
Punctuality
Work Knowledge
Quality of Work
Application & Efficiency
Safety Consciousness
Cooperation with Superiors
Cooperation with Other Trainees
Adherence to CDPLC Rules & Regulations
Maintenance of Trainee Record Book
Situational flexibility
Total
Remarks
…………………………………………………………………………………
Signature of Departmental Head/ Workshop Engineer
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